GX120 160 200 UT2 English PDF

62Z4H000.
book 1
dummyhead
How to use this manual

A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure or a tool that is not
recommended by Honda, must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customers Safety
Proper service and maintenance are essential to the customers safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe

condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety

Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practice, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and

precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs or other stored-energy components. If there is any doubt, put on eye protection.
Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
Protect yourself and others whenever you have engine-power equipment up in the air. Anytime you lift this product with a hoist,
make sure that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way.
Gasoline vapors and hydrogen gasses from battery are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
Use only a nonflammable solvent, not gasoline, to clean parts.
Never store gasoline in an open container.
Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
0-1
62Z4H000.book 2
dummyhead
SPECIFICATIONS 1
SERVICE INFORMATION 2
MAINTENANCE 3
TROUBLESHOOTING 4
COVER 5
FUEL SYSTEM 6
GOVERNOR SYSTEM 7
CHARGING SYSTEM 8
IGNITION SYSTEM 9
STARTING SYSTEM 10
OTHER ELECTRICAL 11
MUFFLER 12
CYLINDER HEAD 13
CRANKCASE 14
REDUCTION UNIT 15
WIRING DIAGRAMS 16
INDEX
0-2
62Z4H000.book 3
dummyhead

INTRODUCTION
This manual covers the service and repair procedures for Honda GX120UT2/160UT2/200UT2.
All information contained in this manual is based on the latest product information available at the time of printing. We reserve the
right to make changes at anytime without notice.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, by any means, electronic,
mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher. This includes text, figures, and
tables.
As you read this manual, you will find information that is preceded by a symbol. The purpose of this message is to help
prevent damage to this Honda product, other property, or the environment.
SAFETY MESSAGES
Your safety, and the safety of others, are very important. To help you make informed decisions, we have provided safety messages
and other safety information throughout this manual. Of course, it is not practical or possible to warn you about all the hazards
associated with servicing these products. You must use your own good judgement.
You will find important safety information in a variety of forms, including:
Safety Labels on the product.
Safety Messages preceded by a safety alert symbol and one of three signal words, DANGER, WARNING, or CAUTION.
These signal words mean:
You WILL be KILLED or SERIOUSLY HURT if you dont follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.
You CAN be HURT if you dont follow instructions.

Instructions how to service these products correctly and safely.
ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE
BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda
Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF
MAINTENANCE ON Honda products.
Honda Motor Co., Ltd.

SERVICE PUBLICATION OFFICE
Date of Issue: May 2011
0-3
62Z4H000.book 4
dummyhead

SERVICE RULES
Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Hondas design
specifications may damage the unit.
Use the special tools designed for the product.
Install new gaskets, O-rings, etc. when reassembling.
When torquing bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless
a particular sequence is specified.
Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
After reassembly, check all parts for proper installation and operation.
Many screws used in this machine are self-tapping. Be aware that cross-threading or overtightening these screws will strip the
threads and ruin the hole.
Use only metric tools when servicing this unit. Metric bolts, nuts and screws are not interchangeable with non-metric fasteners. The
use of incorrect tools and fasteners will damage the unit.
SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the part(s) with new one(s) before assembly.
Use the recommend engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1:1).
Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).
Use marine grease (water resistant urea based grease).
Apply a locking agent. Use a medium strength locking agent unless otherwise specified.
Apply sealant.
Use automatic transmission fluid.
( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

page 1-1 Indicates the reference page.
0-4
62Z4H000.book 5
dummyhead

ABBREVIATIONS
Throughout this manual, the following abbreviations are used to identify the respective parts or systems
Abbrev. term Full term
ACG Alternator
API American Petroleum institute
Approx. Approximately
Assy. Assembly
ATDC After Top Dead Center
ATF Automatic Transmission Fluid
ATT Attachment
BAT Battery
BDC Bottom Dead Center
BTDC Before Top Dead Center
BARO Barometric Pressure
CKP Crankshaft Position
Comp. Complete
CMP Camshaft Position
CYL Cylinder
DLC Data Link Connector
EBT Engine Block Temperature
ECT Engine Coolant Temperature
ECM Engine Control Module
EMT Exhaust Manifold Temperature
EOP Engine Oil Pressure
EX Exhaust
F Front or Forward
GND Ground
HO2S Heated Oxygen sensor
IAC Idle Air Control
IAT Intake Air Temperature
I.D. Inside diameter
IG or IGN Ignition
IN Intake
INJ Injection
L. Left
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
O.D. Outside Diameter
OP Optional Part
PGM-FI Programmed-Fuel Injection
P/N Part Number
Qty Quantity
R. Right
SAE Society of Automotive Engineers
SCS Service Check Signal
STD Standard
SW Switch
TDC Top Dead Center
TP Throttle Position
VTEC Variable Valve Timing & Valve Lift Electronic Control
Bl Black G Green Br Brown Lg Light green

Y Yellow R Red O Orange P Pink
Bu Blue W White Lb Light blue Gr Gray
0-5
62Z4H000.book 1
dummytext
1. SPECIFICATIONS
SERIAL NUMBER LOCATION 1-2 ENGINE SPECIFICATIONS 1-11
P.T.O. TYPE VARIATION1-2 PERFORMANCE CURVES 1-12
DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS 1-15

SPECIFICATIONS 1-10
P.T.O. DIMENSIONAL DRAWINGS 1-21
1-1
62Z4H000.book 2
dummyhead
SPECIFICATIONS
SERIAL NUMBER LOCATION
SPECIFICATIONS
The model [1], type [2] and engine serial number [3] are stamped on the crankcase.
Refer to them when ordering parts or making technical inquiries.
[1]
[2]
[3]
P.T.O. TYPE VARIATION

GX120UT2
P.T.O. type H L P Q R
HH QH2 QH QX QX RH
Type HX2 HX4 LX4 PX2 QA2 QX2 QX4 QX9
Q4 6 Q4 C9 S2 Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Control base Manual Standard
Cyclone
standard
Remote Internal
EXP
Cyclone
Fixed throttle operation
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Starter motor/combination switch
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
Chain Without clutch
With clutch
1-2
62Z4H000.book 3
dummyhead
SPECIFICATIONS
P.T.O. type S T U V W
SH SM UX VEX WM
Type SX4 TX2
Q4 A7 U 9 A3
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-3
62Z4H000.book 4
dummyhead
SPECIFICATIONS
GX160UT2
P.T.O. type H L P Q
HH2 HH HXE LH QA QB QH2 QH
Type HX2 HX4 LX2 LX4 PXU QA2
6 Q4 8 Q4 X4 C2 6 Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-4
62Z4H000.book 5
dummyhead
SPECIFICATIONS
P.T.O. type Q R
QM QM QM QX QX QX QX QX RH
Type QX2 QX4 QX9 RH2 RX4
C6 C8 D6 C9 E2 E8 S2 U Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-5
62Z4H000.book 6
dummyhead
SPECIFICATIONS
P.T.O. type R S T U V
RX SD1 SH SM SM TXC UX VSD
Type SX4 SX9 SXU TX2 TX4 VA2
U 6 Q4 C7 C9 9 U 9
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-6
62Z4H000.book 7
dummyhead
SPECIFICATIONS
P.T.O. type V W
VXE VXU WK WK WM
Type VX2
9 1 S T2 BO
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-7
62Z4H000.book 8
dummyhead
SPECIFICATIONS
GX200UT2
P.T.O. type H L P Q R
QH2 QH QX QX QX QX RH
Type HX2 LX4 PXU QX2 QX4 QX9 RH2
6 Q4 B2 C9 E2 E4 Q4
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-8
62Z4H000.book 9
dummyhead
SPECIFICATIONS
P.T.O. type R S T V
RX SH VSD VXU
Type RX4 SX4 SX9 SXU TX2 VXU
U Q4 9 1
Air cleaner Dual
Dual silent
Cyclone
Low profile
Oil bath
Semi dry
Muffler Standard
Silent
Low profile
Spark arrester
Fuel gauge
Cyclone
standard
Remote Internal
EXP
Cyclone
Charge coil 1A
3A
7A
Lamp coil 12 V 15 W
12 V 25 W
12 V 50 W
Oil level switch
Engine stop switch
Oil alert unit
Circuit protector
Reduction Gear
With clutch
1-9
62Z4H000.book 10
dummyhead
SPECIFICATIONS
DIMENSIONS AND WEIGHTS SPECIFICATIONS
P.T.O. type GX120UT2/T2 GX160UT2/T2 GX200UT2/T2
Overall length H* 370 mm (14.6 in) 377 mm (14.8 in) 386 mm (15.2 in)
L* 332 mm (13.1 in) 343 mm (13.5 in) 352 mm (13.9 in)
P, Q, T * 305.5 mm (12.03 in) 312.5 mm (12.30 in) 321.5 mm (12.66 in)
R* 384 mm (15.1 in) 391 mm (15.4 in) 400 mm (15.7 in)
S* 297 mm (11.7 in) 304 mm (12.0 in) 313 mm (12.3 in)
U* 309.8 mm (12.20 in) 316.8 mm (12.47 in)
V* 315.5 mm (12.42 in) 322.5 mm (12.70 in) 331.5 mm (13.05 in)
W* 317.5 mm (12.50 in) 329.5 mm (12.97 in)
Overall width H* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
L* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
P, Q, T * 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
R* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
S* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
U* 346 mm (13.6 in) 362 mm (14.3 in)
V* 346 mm (13.6 in) 362 mm (14.3 in) 376 mm (14.8 in)
W* 346 mm (13.6 in) 362 mm (14.3 in)
Overall height 329 mm (13.0 in)/ 346 mm (13.6 in)/ 346 mm (13.6 in)/
H*
318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/ 346 mm (13.6 in)/
L*
318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/ 346 mm (13.6 in)/
P, Q, T *
318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/ 346 mm (13.6 in)/
R*
318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/ 346 mm (13.6 in)/
S*
318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/
U*
318 mm (12.5 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/ 346 mm (13.6 in)/
V*
318 mm (12.5 in) 335 mm (13.2 in) 335 mm (13.2 in)
329 mm (13.0 in)/ 346 mm (13.6 in)/
W*
318 mm (12.5 in) 335 mm (13.2 in)
Dry weight H* 15.5 kg (34.2 lbs) 17.6 kg (38.8 lbs) 18.6 kg (41.0 lbs)
L* 14.0 kg (30.9 lbs) 16.1 kg (35.5 lbs) 17.1 kg (37.7 lbs)
P, Q, T * 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
R* 18.0 kg (39.7 lbs) 20.0 kg (44.1 lbs) 21.0 kg (46.3 lbs)
S* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
U* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs)
V* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs) 16.1 kg (35.5 lbs)
W* 13.0 kg (28.7 lbs) 15.1 kg (33.3 lbs)
Operating weight H* 18.0 kg (39.7 lbs) 21.1 kg (46.5 lbs) 22.1 kg (48.7 lbs)
L* 16.5 kg (36.4 lbs) 19.6 kg (43.2 lbs) 20.6 kg (45.4 lbs)
P, Q, T * 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) 19.6 kg (43.2 lbs)
R* 21.0 kg (46.3 lbs) 24.0 kg (52.9 lbs) 25.0 kg (55.1 lbs)
S* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) 19.6 kg (43.2 lbs)
U* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs)
V* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs) 19.6 kg (43.2 lbs)
W* 15.5 kg (34.2 lbs) 18.6 kg (41.0 lbs)
*: P. T. O. type. (page 1-2)
1-10
62Z4H000.book 11
dummyhead
SPECIFICATIONS
ENGINE SPECIFICATIONS
Model GX120UT2/T2 GX160UT2/T2 GX200UT2/T2
Description code GCBMT/GCBNT GCBPT/GCBRT GCBTT/GCBUT
Type 4 stroke, overhead valve, single cylinder, inclined by 25
Displacement 118 cm3 (7.2 cuin) 163 cm3 (9.9 cuin) 196 cm3 (12.0 cuin)
Bore x stroke 66.0 x 42.0 mm 68.0 x 45.0 mm 68.0 x 54.0 mm
(2.60 x 1.65 in) (2.68 x 1.77 in) (2.68 x 2.13 in)
Net power (SAE J1349) *1 2.6 kW (3.5 HP)/ 3.6 kW (4.9 HP)/ 4.1 kW (5.6 HP)/
3,600 min-1 (rpm) 3,600 min-1 (rpm) 3,600 min-1 (rpm)
Continuous rated power 2.1 kW (2.9 HP)/ 2.9 kW (3.9 HP)/ 3.7 kW (5.0 HP)/
Maximum net torque 7.3 Nm (0.7 kgfm, 5.4 10.3 Nm (1.1 kgfm, 7.6 12.4 Nm (1.3 kgfm, 9
(SAE J1349) *1 lbfft)/2,500 min-1 (rpm) lbfft)/2,500 min-1 (rpm) lbfft)/2,500 min-1 (rpm)
Compression ratio 8.5 : 1 9.0 : 1 8.5 : 1
Fuel consumption (at 1.0 Liter (0.26 US gal, 0.22 1.4 Liters (0.37 US gal, 1.7 Liters (0.45 US gal,
continuous rated power) Imp gal)/h 0.31 Imp gal)/h 0.37 Imp gal)/h
Ignition system C.D.I. (Capacitor Discharge Ignition) type magneto ignition
Ignition timing B.T.D.C. 20/ B.T.D.C. 18/ B.T.D.C. 20/
Recommended spark plug BPR6ES (NGK)/W20EPR-U (DENSO)
Lubrication system Forced splash
Oil capacity 0.56 Liter 0.58 Liter 0.60 Liter
(0.59 US qt, 0.49 Imp qt) (0.61 US qt, 0.51 Imp qt) (0.63 US qt, 0.53 Imp qt)
Recommended oil SAE 10W-30 API service classification SJ or higher
Cooling system Forced air
Starting system Recoil, Recoil and Starter Recoil, Recoil and Starter
Recoil Starter
motor motor
Stopping system Ignition exciter coil circuit open
Carburetor Horizontal type, butterfly valve
Air cleaner Dual type, Dual silent type, Semi dry type, Dual silent type,
Oil bath type, Cyclone type Cyclone type
Governor Mechanical centrifugal
Breather system Reed valve type
Fuel used Unleaded gasoline with a pump octane rating 86 or higher
Fuel tank capacity 2.0 Liters
3.1 Liters (0.82 US gal, 0.68 Imp gal)
(0.53 US gal, 0.44 Imp gal)
Reduction Gear type 0.15 Liter (0.16 US qt, 0.13 Imp qt)
case oil Chain type
capacity (without Shared with engine oil
clutch)
Chain type
0.50 Liter (0.53 US qt, 0.44 Imp qt)
(with clutch)
Clutch Type Centrifugal
Engagement
1,800 min-1 (rpm)
start
Lock 2,200 min-1 (rpm)
*1: The power rating of the engine indicated in this document is the net power output tested on a production engine for the engine
model and measured in accordance with SAE J1349 at 3,600 rpm (net power) and at 2,500 rpm (max net torque). Mass production
engines may vary from this value. Actual power output for the engine installed in the final machine will vary depending on numerous
factors, including the operating speed of the engine in application, environmental conditions, maintenance, and other variables.
1-11
62Z4H000.book 12
dummyhead
SPECIFICATIONS
PERFORMANCE CURVES
GX120
(Nm) (lbfft) (kgfm)

7.5
5.5
0.75
TORQUE
NET TORQUE
7.0
5.0 0.70
6.5
(kW) (HP) (PS)

3 4 4
NET POWER
3 3
2
OUTPUT
2 2
1 1
RECOMMENDED OPERATING SPEED RANGE
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-12
62Z4H000.book 13
dummyhead
SPECIFICATIONS
GX160
(Nm) (lbfft) (kgfm)

11
8.0 1.1
TORQUE
7.5
10
NET TORQUE 1.0
7.0
9
0.9
(kW)
4
(HP) (PS)
5 5
NET POWER
3 4 4
OUTPUT
3 3
2
2 2
1 1
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-13
62Z4H000.book 14
dummyhead
SPECIFICATIONS
GX200
(Nm) (lbfft) (kgfm)

13
9.5 1.3
9.0
12
TORQUE
NET TORQUE 1.2

8.5
11
8.0 1.1
10
(kW)
5
(HP) (PS)
6 6
NET POWER 5 5
3 4 4
OUTPUT
3 3
2
2 2
1 1
0 0 0
2000 3000 3600
ENGINE SPEED (rpm)
1-14
62Z4H000.book 15
dummyhead
SPECIFICATIONS
DIMENSIONAL DRAWINGS
*: P.T.O. type. (page 1-2)
GX120 (WITHOUT REDUCTION)
Unit: mm (in)
Dual/dual silent: 160 (6.3)

Cyclone: 166 (6.5)
Oil bath: 157 (6.2)
Semi dry: 156 (6.1) Dual/dual silent: 317 (12.5)
115 (4.5) 231 (9.1) Cyclone/Oil bath: 330 (13.0)
Semi dry: 314 (12.4)
Standard: 91 (3.6)
Silent: 104 (4.1)
346 (13.6)
UT2: 329
(13.0)
T2: 318
(12.5)
106 (4.2)
S type*: 75.5 (2.97)

162 (6.4) U, W type*: 75.2 (2.96)
5 (0.2)
96 (3.8)
39.5 (5.56)
P type*: 305.5 (12.03)
Q type*: 305.5 (12.03)
S type*: 297 (11.7)
80 (3.1)
T type*: 305.5 (12.03)
U type*: 309.8 (12.20)
V type*: 315.5 (12.42)
W type*: 317.5 (12.50)
1-15
62Z4H000.book 16
dummyhead
SPECIFICATIONS
GX120 (WITH REDUCTION)
Unit: mm (in)
115 (4.5)
H type*: 45.1 (1.78)

L type*: 66.1 (2.60)
R type*: 89.7 (3.53) H type*: 185.9 (7.32)
L type*: 164.9 (6.49)
R type*: 141.3 (5.56)
346 (13.6) 91 (3.6) 160 (6.3)
317
(12.5)
UT2: 329
(13.0)
T2: 318
(12.5)
H, L type*: 106 (4.2)

R type*: 91.8 (3.61)
H type*: 151.2 (5.95)

162 (6.4) L type*: 110 (4.3)
5 (0.2) R type*: 162.8 (6.41)
96 (3.8)
39.5 (5.56)
H type*: 370 (14.6)

L type*: 332 (13.1)
80 (3.1) R type*: 384 (15.1)
1-16
62Z4H000.book 17
dummyhead
SPECIFICATIONS
Unit: mm (in)
121 (4.8)
70 (2.8)

Cyclone: 168 (6.6)
Oil bath: 159 (6.3)
123 (4.8) 239 (9.4) Semi dry: 156 (6.1) Dual/dual silent: 337 (13.3)
Cyclone/Oil bath/Semi dry:
333 (13.1)
419 (16.5) Standard: 93 (3.7)

Silent: 106 (4.2)
362 (14.3)
UT2: 346
(13.6)
T2: 335
(13.2)
106 (4.2)
S type*: 75.5 (2.97)

U, W type*: 75.2 (2.96)
162 (6.4)
5 (0.2)
96 (3.8)
39.5 (5.56)
P type*: 312.5 (12.30)
Q type*: 312.5 (12.30)
S type*: 304 (12.0)
80 (3.1) T type*: 312.5 (12.30)
U type*: 316.8 (12.47)
V type*: 322.5 (12.70)
W type*: 329.5 (12.97)
1-17
62Z4H000.book 18
dummyhead
SPECIFICATIONS
Unit: mm (in)
121 (4.8)
70 (2.8)
123 (4.8)
H type*: 45.1 (1.78)

L type*: 66.1 (2.60)
R type*: 89.7 (3.53) H type*: 193.9 (7.63)
L type*: 172.9 (6.81)
R type*: 149.3 (5.88)
419 (16.5)
362 (14.3) 93 (3.7) 160 (6.3)
UT2: 346
(13.6)
T2: 335 337
(13.2) (13.3)
H, L type*: 106 (4.2)

R type*: 91.8 (3.61)
H type*: 151.2 (5.95)

L type*: 114.5 (4.51)
162 (6.4) R type*: 162.8 (6.41)
5 (0.2)
96 (3.8)
39.5 (5.56) H type*: 377 (14.8)
L type*: 343 (13.5)
R type*: 391 (15.4)
80 (3.1)
1-18
62Z4H000.book 19
dummyhead
SPECIFICATIONS
Unit: mm (in)
121 (4.8)
70 (2.8)

Cyclone: 168 (6.6)
Oil bath: 159 (6.3)
Semi dry: 156 (6.1) Dual/dual silent: 339 (13.3)
123 (4.8) 253 (10.0)
Cyclone/Oil bath/Semi dry:
335 (13.2)
433 (17.0)
376 (14.8) 106 (4.2)
UT2: 346
(13.6)
T2: 335
(13.2)
106 (4.2)
S type*: 75.5 (2.97)

U, W type*: 75.2 (2.96)
162 (6.4)
5 (0.2)
96 (3.8)
39.5 (5.56)
P type*: 321.5 (12.66)
Q type*: 321.5 (12.66)
S type*: 313 (12.3)
80 (3.1)
T type*: 321.5 (12.66)
V type*: 331.5 (13.05)
1-19
62Z4H000.book 20
dummyhead
SPECIFICATIONS
Unit: mm (in)
121 (4.8)
70 (2.8)
123 (4.8)
H type*: 45.1 (1.78)
L type*: 66.1 (2.60)
R type*: 89.7 (3.53) H type*: 207.9 (8.19)
L type*: 186.9 (7.36)
R type*: 163.3 (6.43)
433 (17.0)
376 (14.8) 106 (4.2) 160 (6.3)
UT2: 346
(13.6) 339
(13.3)
T2: 335
(13.2)
H, L type*: 106 (4.2)

R type*: 91.8 (3.61)
H type*: 151.2 (5.95)

L type*: 114.5 (4.51)
162 (6.4) R type*: 162.8 (6.41)
5 (0.2)
96 (3.8)
39.5 (5.56) H type*: 386 (15.2)
L type*: 352 (13.9)
R type*: 400 (15.7)
80 (3.1)
1-20
62Z4H000.book 21
dummyhead
SPECIFICATIONS
P.T.O. DIMENSIONAL DRAWINGS
*: P.T.O. type. (page 1-2)
WITHOUT REDUCTION
Unit: mm (in)
45 45
M8 x 1.25
65.1 (2.56)
M8 x 1.25 (4 PLACES)
88 (3.5)
CRANKSHAFT (P.T.O.)
P type* Unit: mm (in) Q type* Unit: mm (in)
5/16-24UNF-2B 61.7 (2.43)

3/4-16UNF-2ARH
4.73 4.78 58.5 (2.30)
61.7 (2.43)
(0.186 0.188)
58.5 (2.30)
GX120: 78 (3.1)
GX160/GX200:
74 (2.9)
16.26 16.36
22.5 (0.89) (0.640 0.644) 17 (0.7)
19.025 19.050 GX120: 78 (3.1) GX120: 19.000 19.050

(0.7490 0.4500) GX160/GX200: 74 (2.9) (0.7480 0.7500)
GX160/GX200: 19.025 19.050
(0.7490 0.7500)
1-21
62Z4H000.book 22
dummyhead
SPECIFICATIONS
S type* Unit: mm (in) T type* Unit: mm (in)

53.2 (2.09)
5.00 5.03 M8 X 1.25

50 (2.0) 61.7 (2.43)
(0.197 0.198) 5/8-18UNF-2ARH
58.5 (2.30)
GX120:
78 (3.1)
GX160/GX200:
74 (2.9)
GX120: 14.90 15.00 23 (0.9)

(0.587 0.591)
GX160/GX200: 16.90 17.00 GX120: 17.957 17.984 (0.7070 0.7080) 22.5 (0.89)
(0.665 0.669) GX160/GX200: 19.947 19.980 (0.7853 0.7866) 15.852 15.870 (0.6241 0.6248)
GX120: 78 (3.1)
GX160/GX200: 74 (2.9)
U type* Unit: mm (in) V type* Unit: mm (in)
1/2-20UNF-2ARH 5/16-24UNF-2B
66 (2.6)
TAPER 2-1/4
9.90 10.00 (0.390 0.394) 56 (2.2) 71.7 (2.82)
33.5 (1.32)
3.954 3.984
(0.1557 0.1569) 8 (0.3)
14.225 14.275 (0.5600 0.5620)
18.927 19.177
19.000 19.050 (0.7480 0.7500) (0.7452 0.7550)
19.830 19.843 (0.7807 0.7812)

GX120: 78 (3.1)
GX120: 78 (3.1)
GX160/GX200: 74 (2.9)
GX160/GX200: 74 (2.9)
W type* Unit: mm (in)
GX120: M14 x 1.5 GX120: 73.7 (2.90)

GX160: M18 x 1.5 GX160: 78.7 (3.10)
58.7 (2.31)
GX120: 78 (3.1)
GX160: 74 (2.9)
GX120: 12.5 (0.49)

GX160: 15.9 (0.63)
GX120: 17.976 17.994 GX120: 70 (2.8)
(0.7077 0.7084) GX160: 75 (3.0)
GX160: 19.972 19.993
(0.7863 0.7871)
1-22
62Z4H000.book 23
dummyhead
SPECIFICATIONS
WITH REDUCTION
H type* Unit: mm (in)
45.1 (1.78)
P.T.O. SHAFT
4.724 4.774
(0.1860 0.1880) 50 (2.0)
41.25
(1.624)
48 (1.9)
16.23 16.36
(0.639 0.644) 19.037 19.050
(0.7495 0.7500)
REDUCTION UNIT
L type* Unit: mm (in)
P.T.O. SHAFT 45 45
M8 x 1.25
5.00 5.03 53.2 (2.09)
(0.197 0.198) 50 (2.0)
65.1
41.25
(2.56)
(1.624)
54 (2.1)
23 (0.9)
M8 x 1.25 (6 PLACES) GX120: 17.957 17.984

(0.7070 0.7080)
66.1 (2.60)
GX160/GX200: 19.947 19.980
(0.7853 0.7866)
GX120: 14.90 15.00 (0.587 0.591)

93.5 (3.68)
GX160/GX200: 16.90 17.00 (0.665 0.669)
REDUCTION UNIT
1-23
62Z4H000.book 24
dummyhead
SPECIFICATIONS
R type* Unit: mm (in)
45
M8 x 1.25
45
52.7 (2.07)
7.000 7.036
(0.2756 0.2770)
70
(2.8) 50
(2.0)
50 (2.0)
70 17.90 18.00 25 (1.0)

(2.8) (0.705 0.709)
P.T.O. SHAFT
21.947 21.980 (0.8641 0.8654)
89.7 (3.53)
REDUCTION UNIT M8 x 1.25 (4 PLACES)
1-24
62Z4H000.book 1
dummytext
2. SERVICE INFORMATION
MAINTENANCE STANDARDS 2-2 TOOLS 2-8
TORQUE VALUES 2-6 HARNESS AND TUBE ROUTING 2-11
LUBRICATION & SEAL POINTS2-7
2-1
62Z4H000.book 2
dummyhead
SERVICE INFORMATION
MAINTENANCE STANDARDS
SERVICE INFORMATION
GX120
Unit: mm (in)
Part Item Standard Service limit
Engine Maximum speed (at no load) 3,900 100 min-1 (rpm)
Idle speed + 200
1,400 min-1 (rpm)
150
Cylinder compression 0.49 0.69 MPa (5.0 7.0 kgf/cm2, 71

100 psi)/600 min-1 (rpm)
Cylinder head Warpage 0.10 (0.004)
Cylinder Sleeve I.D. 60.000 60.015 (2.3622 2.3628) 60.165 (2.3687)
Piston Skirt O.D. 59.965 59.985 (2.3608 2.3616) 59.845 (2.3561)
Piston-to-cylinder clearance 0.015 0.050 (0.0006 0.0020) 0.12 (0.005)
Piston pin bore I.D. 13.002 13.008 (0.5119 0.5121) 13.048 (0.5137)
Piston pin Pin O.D. 12.994 13.000 (0.5116 0.5118) 12.954 (0.5100)
Piston pin-to-piston pin bore
0.002 0.014 (0.0001 0.0006) 0.08 (0.003)
clearance
Piston rings Ring side clearance Top 0.035 0.070 (0.0014 0.0028) 0.15 (0.006)
Second 0.045 0.080 (0.0018 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 0.350 (0.0079 0.0138) 1.0 (0.04)
Second 0.350 0.500 (0.0138 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 0.7 (0.01 0.03) 1.0 (0.04)
Ring width Top 0.950 0.970 (0.0374 0.0382) 0.93 (0.037)
Second 0.940 0.960 (0.0370 0.0378) 0.92 (0.036)
Connecting Small end I.D. 13.005 13.020 (0.5120 0.5126) 13.07 (0.515)
rod Big end side clearance 0.1 0.7 (0.004 0.028) 1.1 (0.04)
Big end I.D. 26.020 26.033 (1.0244 1.0249) 26.066 (1.026)
Big end oil clearance 0.040 0.063 (0.0016 0.0025) 0.12 (0.005)
Crankshaft Crankpin O.D. 25.970 25.980 (1.0224 1.0228) 25.92 (1.020)
Crankshaft runout 0.10 (0.004)
Cylinder barrel Camshaft journal I.D. 14.000 14.018 (0.5512 0.5519) 14.048 (0.5531)
Crankcase Camshaft journal I.D.
14.000 14.018 (0.5512 0.5519) 14.048 (0.5531)
cover
Valves Valve clearance IN 0.15 0.02 (0.006 0.001)
EX 0.20 0.02 (0.008 0.001)
Valve stem O.D. IN 5.468 5.480 (0.2153 0.2157) 5.318 (0.2094)
EX 5.425 5.440 (0.2136 0.2142) 5.275 (0.2077)
Valve guide I.D. IN/EX 5.500 5.512 (0.2165 0.2170) 5.572 (0.2194)
Guide-to-stem IN 0.020 0.044 (0.0008 0.0017) 0.10 (0.004)
clearance EX 0.060 0.087 (0.0024 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 5.2 (0.19 0.20)
installation height
Valve seat width IN/EX 0.70 0.90 (0.028 0.035) 2.0 (0.08)
Valve spring free length 30.5 (1.20) 29.0 (1.14)
Valve spring perpendicularity 1.5 max.
Camshaft Cam height IN 27.500 27.900 (1.0827 1.0984) 27.450 (1.0807)
EX 27.547 27.947 (1.0845 1.1003) 27.500 (1.0827)
Camshaft O.D. 13.966 13.984 (0.5498 0.5506) 13.916 (0.5479)
Carburetor Main jet BE60W A #62
BE99A A #60
BE61M A #62
BE99B A #62
Pilot screw opening BE60W A 2-1/8 turns out
BE99A A 1-5/8 turns out
BE61M A 2-1/8 turns out
BE99B A 2-1/8 turns out
Float height 13.7 (0.54)
Spark plug Gap 0.70 0.80 (0.028 0.031)
Spark plug cap Resistance (20C/68F) 7.5 12.5 k
Ignition coil Air gap 0.2 0.6 (0.01 0.02)
Primary resistance 0.6 0.9
Secondary resistance 5.6 6.9 k
2-2
62Z4H000.book 3
dummyhead
SERVICE INFORMATION
Lamp coil Resistance 12 V 50 W 0.18 0.23
Reduction unit P.T.O. shaft journal O.D. 19.929 19.950 (0.7846 0.7854)
(Chain type: P.T.O. shaft journal I.D.
without clutch) 20.000 20.021 (0.7874 0.7882)
(Crankcase cover)
Reduction unit Clutch friction disc thickness 3.5 (0.14) 3.0 (0.12)
(Chain type: Clutch plate warpage 0.10 (0.004)
with clutch)
GX160
Unit: mm (in)
Idle speed + 200
1,400 min-1 (rpm)
150
Cylinder compression 0.49 0.69 MPa (5.0 7.0 kgf/cm2, 71

100 psi)/600 min-1 (rpm)
Piston Skirt O.D. 67.985 67.995 (2.6766 2.6770) 67.845 (2.6711)
Piston pin Pin O.D. 17.994 18.000 (0.7084 0.7087) 17.954 (0.7068)
0.002 0.014 (0.0001 0.0006) 0.08 (0.003)
clearance
Second 0.045 0.080 (0.0018 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 0.350 (0.0079 0.0138) 1.0 (0.04)
Second 0.350 0.500 (0.0138 0.0197) 1.0 (0.04)
Oil (side rail) 0.10 0.35 (0.004 0.014) 1.0 (0.04)
Ring width Top 0.925 0.945 (0.0364 0.0372) 0.905 (0.0356)
Second 0.940 0.960 (0.0370 0.0378) 0.92 (0.036)
Big end I.D. 30.020 30.033 (1.1819 1.1824) 30.066 (1.1837)
14.000 14.018 (0.5512 0.5519) 14.048 (0.5531)
cover
EX 0.10 0.02 (0.004 0.001)
Valve stem O.D. IN 5.468 5.480 (0.2153 0.2157) 5.318 (0.2094)
EX 5.425 5.440 (0.2136 0.2142) 5.275 (0.2077)
Guide-to-stem IN 0.020 0.044 (0.0008 0.0017) 0.10 (0.004)
clearance EX 0.060 0.087 (0.0024 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 5.2 (0.19 0.20)
installation height
Valve seat width IN 0.70 0.90 (0.028 0.035) 2.0 (0.08)
EX 0.90 1.10 (0.035 0.043) 2.0 (0.08)
Camshaft Cam height IN/EX 27.503 27.903 (1.0828 1.0985) 27.450 (1.0807)
Camshaft O.D. 13.966 13.984 (0.5498 0.5506) 13.916 (0.5479)
2-3
62Z4H000.book 4
dummyhead
SERVICE INFORMATION
Carburetor Main jet BE54C A #70
BE54D A #68
BE66U A #68
BE54P A #70
BE54J B #68
Pilot screw opening BE54C A 2-1/4 turns out
BE54D A 1-7/8 turns out
BE66U A 1-7/8 turns out
BE54P A 2-1/2 turns out
BE54J B 1-7/8 turns out
Spark plug Gap 0.70 0.80 (0.028 0.031)
Starter motor Brush length 11.0 (0.43) 6.0 (0.24)
Mica depth 1.6 (0.06) 1.1 (0.04)
Charge coil Resistance 1A 3.15 3.85
7A 0.22 - 0.30
Lamp coil Resistance 12 V 25 W 0.36 - 0.46
12 V 50 W 0.18 - 0.23
without clutch) 20.000 20.021 (0.7874 0.7882)
(Crankcase cover)
with clutch)
GX200
Unit: mm (in)
Idle speed + 200
1,400 min-1 (rpm)
150
Cylinder compression 0.35 MPa (3.6 kgf/cm2, 51 psi)/600 min-1
(rpm)
Piston Skirt O.D. 67.965 67.985 (2.6758 2.6766) 67.845 (2.6711)
Piston pin Pin O.D. 17.994 18.000 (0.7084 0.7087) 17.954 (0.7068)
0.002 0.014 (0.0001 0.0006) 0.08 (0.003)
clearance
Second 0.045 0.080 (0.0018 0.0032) 0.15 (0.006)
Ring end gap Top 0.200 0.350 (0.0079 0.0138) 1.0 (0.04)
Second 0.350 0.500 (0.0138 0.0197) 1.0 (0.04)
Oil (side rail) 0.2 0.7 (0.01 0.03) 1.0 (0.04)
Ring width Top 0.950 0.970 (0.0374 0.0382) 0.93 (0.037)
Second 0.940 0.960 (0.0370 0.0378) 0.92 (0.036)
Big end I.D. 30.020 30.033 (1.1819 1.1824) 30.066 (1.1837)
14.000 14.018 (0.5512 0.5519) 14.048 (0.5531)
cover
2-4
62Z4H000.book 5
dummyhead
SERVICE INFORMATION
EX 0.20 0.02 (0.008 0.001)
Valve stem O.D. IN 5.468 5.480 (0.2153 0.2157) 5.318 (0.2094)
EX 5.425 5.440 (0.2136 0.2142) 5.275 (0.2077)
Guide-to-stem IN 0.020 0.044 (0.0008 0.0017) 0.10 (0.004)
clearance EX 0.060 0.087 (0.0024 0.0034) 0.12 (0.005)
Valve guide
IN 4.8 5.2 (0.19 0.20)
installation height
Valve seat width IN/EX 0.70 0.90 (0.028 0.035) 2.0 (0.08)
Camshaft Cam height IN 27.500 27.900 (1.0827 1.0984) 27.450 (1.0807)
EX 27.547 27.947 (1.0845 1.1003) 27.500 (1.0827)
Camshaft O.D. 13.966 13.984 (0.5498 0.5506) 13.916 (0.5479)
Carburetor Main jet BE59L A #75
BE59N A #75
BE59U A #75
BE74Y A #78
Pilot screw opening BE59L A 1-7/8 turns out
BE59N A 1-7/8 turns out
BE59U A 2-1/4 turns out
BE74Y A 2-3/4 turns out
Spark plug Gap 0.70 0.80 (0.028 0.031)
Starter motor Brush length 11.0 (0.43) 6.0 (0.24)
Mica depth 1.6 (0.06) 1.1 (0.04)
Charge coil Resistance 1A 3.15 3.85
without clutch) 20.000 20.021 (0.7874 0.7882)
(Crankcase cover)
with clutch)
2-5
62Z4H000.book 6
dummyhead
SERVICE INFORMATION
TORQUE VALUES
Torque values
Item Tread Dia. (mm)
Nm kgfm lbfft
Crankcase cover bolt (GX120) M6 x 1.0 12 1.2 9
Crankcase cover bolt (GX160/GX200) M8 x 1.25 24 2.4 18
Cylinder head bolt M8 x 1.25 24 2.4 18
Engine oil drain plug bolt M10 x 1.25 18 1.8 13
Connecting rod bolt (GX120/GX200) M7 x 1.0 12 1.2 9
Connecting rod bolt (GX160) M6 x 1.0 10 1.0 7
Rocker arm pivot bolt M8 x 1.25 (Special bolt) 24 2.4 18
Rocker arm pivot adjusting nut M6 x 0.5 (Special nut) 10 1.0 7
Spark plug M14 x 1.25 (Special) 18 1.8 13
Oil level switch joint nut M10 x 1.25 10 1.0 7
Flywheel nut M14 x 1.5 (Special nut) 75 7.6 55
Fuel tank nut/bolt M6 x 1.0 10 1.0 7
Fuel tank joint M10 x 1.25 2 0.2 1.5
Air cleaner elbow nut M6 x 1.0 9 0.9 6.6
Muffler nut M8 x 1.25 24 2.4 18
Drive sprocket bolt (Reduction unit: chain type (without M8 x 1.25 24 2.4 18
clutch))
Reduction case oil drain plug bolt (Reduction unit: gear M12 x 1.5 23 2.3 17
type, chain type (with clutch))
Recoil starter center screw M6 x 1.0 (Special bolt) 5.4 0.6 4.0
Fuel strainer cup M24 x 1.0 3.9 0.4 2.9
STANDARD TORQUE VALUES

Torque values
Item Tread Dia. (mm)
Nm kgfm lbfft
Screw 4 mm 2.1 0.2 1.5
5 mm 4.3 0.4 3.2
6 mm 9 0.9 6.6
Bolt and nut 5 mm 5.3 0.5 3.9
6 mm 10 1.0 7
8 mm 22 2.2 16
10 mm 34 3.5 25
12 mm 54 5.5 40
Flange bolt and nut 5 mm 5.3 0.5 3.9
6 mm 12 1.2 9
8 mm 23 2.3 17
10 mm 40 4.1 30
SH (Small head) flange bolt 6 mm 9 0.9 6.6
CT (Cutting threads) flange bolt (Retightening) 5 mm 5.4 0.6 4.0
6 mm 12 1.2 9
2-6
62Z4H000.book 7
dummyhead
SERVICE INFORMATION
LUBRICATION & SEAL POINTS
Material Location Remarks
Engine oil Crankshaft pin and gear teeth
Piston outer surface, ring groove and piston pin hole
Piston pin outer surface
Piston ring entire surface
Cylinder inner surface
Connecting rod big and small end bearing
Connecting rod bolt threads and seating surface
Camshaft cam profile and journal
Valve lifter pivot, pivot end and slipper surface
Valve stem sliding surface and stem end
Valve rocker arm tappet surface and pivot
Rocker arm pivot threads and pivot
Flywheel nut threads and seating surface
Governor weight holder gear and sliding surface
Governor holder shaft journal
Governor arm shaft journal
Cylinder head bolt threads and seating surface
P.T.O. shaft gear teeth and journal Reduction unit (gear type)
Drive sprocket, P.T.O. shaft gear teeth and journal Reduction unit (chain type:
without clutch)
Drive sprocket, P.T.O. shaft, clutch center gear teeth Reduction unit (chain type:
and journal with clutch)
Clutch disc, clutch plate entire surface
Multi-purpose grease Oil seal lips
Control lever sliding surface
Recoil starter case pulley sliding surface
Recoil starter ratchet sliding surface
Recoil starter spring retainer inside
Use molybdenum oil solution Camshaft cam profile When installing a new
(mixture of the engine oil and camshaft
molybdenum grease in a ratio
of 1:1)
Threebond 2430 or Recoil starter center screw threads
equivalent
LOCTITE 638 or equivalent Limiter cap inside
2-7
62Z4H000.book 8
dummyhead
SERVICE INFORMATION
TOOLS
SPECIAL TOOLS
Special tools used in this manual can be ordered using normal American Honda parts ordering procedures.
Float level gauge Sliding hammer weight Valve guide driver, 5.5 mm
07401-0010000 07741-0010201 07742-0010100
Bearing driver attachment, Bearing driver attachment, Bearing driver attachment,

32 x 35 mm 37 x 40 mm 40 x 42 mm
07746-0010100 07746-0010200 07746-0010900
Bearing driver attachment, Bearing driver attachment, Pilot, 20 mm

42 x 47 mm 52 x 55 mm 07746-0040500
07746-0010300 07746-0010400
Pilot, 22 mm Pilot, 25 mm Pilot, 30 mm

07746-0041000 07746-0040600 07746-0040700
2-8
62Z4H000.book 9
dummyhead
SERVICE INFORMATION
Driver handle Seat cutter, 27.5 mm (45 IN) Seat cutter, 24.5 mm (45 EX)
07749-0010000 07780-0010200 07780-0010100
Seat cutter, 22 mm (45 IN/EX) Flat cutter, 21.5 mm (32 EX) Flat cutter, 22 mm (32 IN)
07780-0010701 07780-0012800 07780-0012601
Flat cutter, 24 mm (32 EX) Flat cutter, 28 mm (32 IN/EX) Flat cutter, 30 mm (32 IN)
07780-0012500 07780-0012100 07780-0012200
Interior cutter, 20.5 mm (60 EX) Interior cutter, 22 mm (60 IN/EX) Interior cutter, 26 mm (60 IN/EX)
07780-0014300 07780-0014202 07780-0014500
Interior cutter, 30 mm (60 IN) Cutter holder, 5.5 mm Flywheel puller set
07780-0014000 07781-0010101 07935-8050004
2-9
62Z4H000.book 10
dummyhead
SERVICE INFORMATION
Bearing remover shaft set, 20 mm Bearing remover shaft handle Bearing remover shaft set, 25 mm
07936-3710600 07936-3710100 07936-ZV10100
Valve guide reamer, 5.510 mm Bearing driver attachment, Bearing driver attachment,
07984-2000001 45 x 50 mm 62 x 64 mm
07946-6920100 07947-6340400
2-10
62Z4H000.book 11
dummyhead
SERVICE INFORMATION
HARNESS AND TUBE ROUTING
Connection of regulator/rectifier, charge/lamp coil and sub wire harness are depending on the application of the engine, therefore,
the routing of these parts is not indicated in this manual.
ENGINE WIRE HARNESS CYLINDER BARREL RIBS
CARBURETOR INSULATOR
GX120:
HIGH-TENSION CORD
CYLINDER BARREL RIBS
CARBURETOR INSULATOR
GX160/GX200:
HIGH-TENSION CORD
ENGINE WIRE
HARNESS
CORD HOOK
IGNITION COIL CONNECTOR
2-11
62Z4H000.book 12
dummyhead
SERVICE INFORMATION
GX120: GX160/GX200:
FUEL TUBE
BREATHER TUBE
HIGH-TENSION CORD
2-12
62Z4H000.book 13
dummyhead
SERVICE INFORMATION
ENGINE STOP SWITCH TYPE
ENGINE STOP SWITCH ONLY:
GX120: GX160/GX200:
CLAMP
ENGINE WIRE HARNESS
ENGINE WIRE HARNESS
ENGINE WIRE HARNESS CONNECTOR ENGINE WIRE HARNESS

ENGINE STOP SWITCH WIRE ENGINE STOP SWITCH WIRE CONNECTOR
WITH OIL LEVEL SWITCH:

HARNESS CLIP
ENGINE STOP SWITCH WIRES
ENGINE WIRE HARNESS
To ignition coil
ENGINE STOP SWITCH CONNECTOR
Bl
Bl
Y Y
To oil level switch
HARNESS CLIP
To engine stop switch
ENGINE WIRE HARNESS CONNECTOR

ENGINE STOP SWITCH WIRE OIL LEVEL SWITCH WIRE
2-13
62Z4H000.book 14
dummyhead
SERVICE INFORMATION
WITH OIL LEVEL SWITCH AND OIL ALERT UNIT:
ENGINE WIRE HARNESS

GX160/GX200:
HARNESS CLIP
CLAMP
ENGINE WIRE HARNESS
ENGINE STOP OIL ALERT UNIT CONNECTOR To ignition coil To oil alert unit
SWITCH WIRES
OIL ALERT
UNIT WIRES
Y Bl
Bl
Bl
Y
Y
To engine stop switch To oil level switch

ENGINE STOP
SWITCH WIRE
HARNESS CLIP
ENGINE WIRE HARNESS CONNECTOR OIL LEVEL SWITCH WIRE

ENGINE STOP SWITCH CONNECTOR
2-14
62Z4H000.book 15
dummyhead
SERVICE INFORMATION
COMBINATION SWITCH (CONTROL BOX) TYPE
ENGINE WIRE HARNESS
CHARGE COIL CORD

STARTER SOLENOID WIRE
ENGINE WIRE HARNESS
CONNECTOR
OIL LEVEL
SWITCH WIRE
TERMINAL
WIRE
OIL ALERT
UNIT WIRE
45 5
CHARGE COIL
CONNECTOR
TERMINAL WIRE
FASTENER TUBE
CHARGE COIL CORD
HARNESS CLIP
HARNESS CLIP PURSE STARTER MOTOR WIRE
OIL LEVEL SWITCH WIRE
LOCK CLIP
TERMINAL WIRE
STARTER MOTOR OIL LEVEL SWITCH

CONNECTOR CONNECTOR
PURSE LOCK CLIP
TERMINAL WIRE
FASTENER TUBE To ignition coil

HARNESS CLIP
PURSE LOCK CLIP
Bl/R
Gr W To charge coil
To starter motor/
To control box Bl/W Bl/W
starter solenoid
Y To oil level switch
To starter motor/
(W)
starter solenoid
2-15
62Z4H000.book 16
dummyhead
SERVICE INFORMATION
WITH CHARGE COIL / LAMP COIL
1 A/3 A CHARGE COIL, 12 V 15 W/12 V 25 W LAMP COIL TYPE:
COIL CORD
CORD GROMMET
CORD CLAMPER
7 A CHARGE COIL TYPE:
COIL CORD
CORD GROMMET
CORD CLAMPER
12 V 50 W LAMP COIL TYPE:
COIL CORD
CORD GROMMET
CORD CLAMPER
2-16
62Z4H000.book 1
dummytext
3. MAINTENANCE
MAINTENANCE SCHEDULE3-2 SPARK PLUG REPLACEMENT 3-11
ENGINE OIL LEVEL CHECK/CHANGE 3-3 SPARK ARRESTER CLEANING 3-12
REDUCTION CASE OIL LEVEL CHECK/ IDLE SPEED CHECK/ADJUSTMENT 3-13

CHANGE3-4
VALVE CLEARANCE CHECK/
AIR CLEANER CHECK/CLEANING/ ADJUSTMENT 3-13
REPLACEMENT3-7
COMBUSTION CHAMBER CLEANING 3-15
SEDIMENT CUP CLEANING 3-10
FUEL TANK AND FILTER CLEANING 3-15
SPARK PLUG CHECK/ADJUSTMENT 3-11
FUEL TUBE CHECK 3-16
3-1
62Z4H000.book 2
dummyhead
MAINTENANCE
MAINTENANCE SCHEDULE
MAINTENANCE
ITEM Perform at every indicated month REGULAR SERVICE PERIOD (2)

or operating hour interval, Every Every Every Refer
whichever comes first. First
Each 3 months 6 months year to
month or
use or or or page
20 hrs.
50 hrs. 100 hrs. 300 hrs.
Engine oil Check level 3-3
Change 3-3
Reduction case oil Check level 3-4
(applicable types) Change 3-5
Air cleaner Check 3-7
(1) (*)(1) 3-7
Clean
(Cyclone type) Every 6 months or 150 hours 3-7
(**) 3-7
Replace
(Cyclone type) Every 2 years or 600 hours 3-7
Sediment cup Clean 3-10
Spark plug Checkadjust 3-11
Replace 3-11
Spark arrester
Clean 3-12
(applicable types)
Idle speed Checkadjust 3-13
Valve clearance Checkadjust 3-13
Combustion chamber Clean After every 500 hours 3-15
Fuel tank and filter Clean 3-15
Fuel tube Check Every 2 years (Replace if necessary) 3-16
(1) Service more frequently when used in dusty areas.
(2) For commercial use, log hours of operation to determine proper maintenance intervals.
(*) Internal vent carburetor with dual element type only.
(**) Replace paper element type only.
3-2
62Z4H000.book 3
dummyhead
MAINTENANCE
ENGINE OIL LEVEL CHECK/CHANGE
CHECK
Place the engine on a level surface.
[1]
Remove the oil filler cap [1] and check the oil level
shown into the oil filler neck [2]. [2]
If the oil level is low, fill with recommended oil to the
upper level of the oil filler neck (page 3-3).
Check that the oil filler packing [3] is in good condition,
replace it if necessary.
Install and tighten the oil filler cap securely.
[3]
CHANGE
Place the engine on a level surface and place a suitable
[2] [4]
container under the drain plug bolt [1].
Remove the oil filler cap [2], drain plug bolt, and drain
plug washer [3] and drain the oil into a suitable
container.
Please dispose of used oil in a manner that is
compatible with the environment. We suggest you take
used oil in a sealed container to your local recycling
center or service station for reclamation. Do not throw it
in the trash, pour it on the ground, or pour it down a
drain.
Used engine oil contains substances that have [1] [3]

been identified as carcinogenic. If repeatedly left in
contact with the skin for prolonged periods, it may
cause skin cancer. Wash your hands thoroughly SAE VISCOSITY GRADES
with soap and water as soon as possible after
contact with used engine oil.
Install the drain plug bolt with a new drain plug washer
and tighten it to the specified torque.
TORQUE: 18 Nm (1.8 kgfm, 13 lbfft)
SAE 10W - 30 is Add the specified amount of recommended oil into the
recommended for engine.
general use. Other
viscosities shown in
OIL CAPACITY:
AMBIENT TEMPERATURE
the chart may be GX120: 0.56 Liter (0.59 US qt, 0.49 Imp qt)
used when the GX160: 0.58 Liter (0.61 US qt, 0.51 Imp qt)
average GX200: 0.60 Liter (0.63 US qt, 0.53 Imp qt)
temperature in your
area is within the RECOMMENDED OIL:
recommended SAE 10W-30
range. API service classification: SJ or higher
After adding the oil, check the oil level.
Check that the oil filler packing [4] is in good condition,
replace it if necessary.
Install and tighten the oil filler cap securely.
Make sure there are no oil leaks.
3-3
62Z4H000.book 4
dummyhead
MAINTENANCE
REDUCTION CASE OIL LEVEL CHECK/
CHANGE
For the chain type (without clutch), refer to the
ENGINE OIL LEVEL CHECK/CHANGE because it
shares the reduction oil with the engine oil (page 3-
3).
CHECK
GEAR TYPE
[1]/[2]
Remove the drain plug bolt [1] and drain plug washer
[2] and check the whether oil flows out.
Fill with recommended oil if it does not flow (page 3-5).
CHAIN TYPE (with clutch)

[1]
Remove the oil filler cap/oil level gauge [1], and wipe
the oil level gauge clean.
Insert the oil level gauge without screwing it into the oil
filler neck.
Remove the oil level gauge and check oil level shown [2]
on the oil level gauge.
If the oil level is low, fill with recommended oil to the
[3]
upper level [2] of the oil level gauge (page 3-5).
Check that the O-ring [3] is in good condition, replace it
if necessary.
Install and tighten the oil filler cap/oil level gauge
securely.
3-4
62Z4H000.book 5
dummyhead
MAINTENANCE
CHANGE
GEAR TYPE
Remove the breathing bolt [1].
[2]/[3] [1]
Remove the drain plug bolt [2] and drain plug washer
[3], tilt the engine and drain the oil into a suitable
container.
drain.
Used engine oil contains substances that have

cause skin cancer. Wash your hands thoroughly
contact with used engine oil. SAE VISCOSITY GRADES
SAE 10W - 30 is Fill the specified amount of recommended engine oil

recommended for into the reduction case.
general use. Other
OIL CAPACITY: 0.15 Liter (0.16 US qt, 0.13 Imp qt)
the chart may be
used when the
RECOMMENDED OIL:
average SAE 10W-30
temperature in your API service classification SJ or higher
area is within the
Install the drain plug bolt with new drain plug washer
recommended AMBIENT TEMPERATURE
range.
Install and tighten the breathing bolt securely.
3-5
62Z4H000.book 6
dummyhead
MAINTENANCE
CHAIN TYPE (with clutch)
Place the engine on a level surface and place a suitable
[2]
container under the drain plug bolt [1].
Remove the oil filler cap/oil level gauge [2], drain plug
bolt and drain plug washer [3] and drain the oil into a
suitable container.
[4] [1]
drain.
Used engine oil contains substances that have [3]

cause skin cancer. Wash your hands thoroughly
SAE VISCOSITY GRADES
contact with used engine oil.
SAE 10W - 30 is Add the specified amount of recommended oil into the
recommended for reduction case.
general use. Other
OIL CAPACITY: 0.50 Liter (0.53 US qt, 0.44 Imp qt)
the chart may be AMBIENT TEMPERATURE
used when the
RECOMMENDED OIL:
average SAE 10W-30
temperature in your API service classification: SJ or higher
area is within the
After adding the oil, check the oil level.
recommended
range. Check that the O-ring [4] is in good condition, replace it
if necessary.
Install and tighten the oil filler cap/oil level gauge
securely.
3-6
62Z4H000.book 7
dummyhead
MAINTENANCE
AIR CLEANER CHECK/CLEANING/
REPLACEMENT
A dirty air filter will restrict air flow to the carburetor,
reducing engine performance. If the engine is operated
in dusty areas, clean the air cleaner more often than
specified in the MAINTENANCE SCHEDULE.
Operating the engine without the air filters or with the

filter installed loosely will allow dirt to enter the engine,
causing rapid engine wear. Install the air filters
securely.
DUAL, DUAL SILENT TYPE
Remove the following:
[1] [2]
Nut [1]
Air cleaner cover [2]
Wing nut [3]
Element Assy.
Grommet [4]
Inner filter (Paper) [5]
Outer filter (Foam) [6]
Carefully check both filters for holes or tears and
replace if damaged.
Clean the filters if they are to be reused (page 3-9).
Installation is in the reverse order of removal. [4]
[3]
Install the air cleaner cover with its long skirt portion
facing forward.
[5] [6]
3-7
62Z4H000.book 8
dummyhead
MAINTENANCE
CYCLONE TYPE
[4]
Bolt (4 x 6 mm) [1] (3) [5]
Pre air cleaner case [2] [1]
Air cleaner guide [3]
Wing nut [4]
Air cleaner cover Assy. [5]
Wing nut [6]
Element Assy.
Grommet [7]
Inner filter (Paper) [8] [3]
Outer filter (Foam) [9] [6]
Carefully check both filters for holes or tears and
replace if damaged. [10]
[7]
Clean the filters if they are to be reused (page 3-9).
[12]
Clean the pre air cleaner case and air cleaner guide.
Check that the air cleaner cover packing [10] is in good
condition, replace it if necessary.
Installation is in the reverse order of removal. [8]
[11]
Install the pre air cleaner case by align it the groove
[11] and tab [12] of the air cleaner cover Assy. [2]
[9]
LOW PROFILE TYPE

Remove the air cleaner case lid spring [1] and air
[2] [1]
cleaner cover [2].
Remove the pre air cleaner element [3].
Carefully check the air cleaner element and replace if
damaged.
Clean the filter if it is to be reused (page 3-9).
Installation is in the reverse order of removal.
[3]
3-8
62Z4H000.book 9
dummyhead
MAINTENANCE
OIL BATH TYPE
[3] [2] [1]
Wing nut [1]
Air cleaner cap [2]
Air cleaner element [4]
Carefully check the element for holes or tears and
replace if damaged. [4]
Clean the element if it is to be reused (page 3-9).
Check the oil contamination and oil level of the cleaner
oil pan [5].
If the oil level is low, fill with the recommended oil to the
upper level [6] of the cleaner oil pan.
If the oil is dirty, clean the cleaner oil pan and add the
recommended oil to the upper level of the cleaner oil
pan.
OIL CAPACITY: 60 cc
[5] [6]
SEMI DRY TYPE
[3] [2] [1]
Wing nut [1]
Air cleaner cap [2]
Air cleaner element [4]
Carefully check the element for holes or tears and
replace if damaged.
Clean the element if it is to be reused (page 3-9).
[4]
ELEMENT CLEANING
FOAM
Clean the filter [1] in warm soapy water, rinse, and allow
[1] Wash Dip
to dry thoroughly, or clean with a non-flammable
solvent and allow to dry thoroughly.
Dip the filter in clean engine oil, and squeeze out all the Squeeze
excess oil. and dry
Excess oil will restrict air flow through the foam element
and may cause the engine to smoke at startup.
Squeeze thoroughly
3-9
62Z4H000.book 10
dummyhead
MAINTENANCE
PAPER
Tap the inner filter [1] lightly several times on a hard
[1]
surface to remove excess dirt, or blow compressed air
lightly (206 kPa (2.11 kgf/cm2, 30 psi) or less) through
the paper filter from the inside out. Never try to brush
the dirt off; brushing will force dirt into the fibers.
SEDIMENT CUP CLEANING
Gasoline is highly flammable and explosive. You

can be burned or seriously injured when handling
fuel.
Keep heat, sparks, and flame away.
Handle fuel only outdoors.
Wipe up spills immediately.
Turn the fuel valve lever [1] to the OFF position.

[1]
Sediment cup [2]
O-ring [3]
Cup filter [4] [6]
Clean the sediment cup and the cup filter with non-
flammable solvent and allow them to dry thoroughly.
Install the cup filter while aligning it with the tip with the
groove of the carburetor and cup filter tab [5] with the
mark [6] of the carburetor.
Install a new O-ring and sediment cup.
Tighten the sediment cup to the specified torque.
TORQUE: 3.9 Nm (0.4 kgfm, 2.9 lbfft)
[5]
Check the installation part of the sediment cup for any
sign of fuel leakage. Align
[4]
[3] [2]
3-10
62Z4H000.book 11
dummyhead
MAINTENANCE
SPARK PLUG CHECK/ADJUSTMENT
Remove the spark plug (page 3-11).
[1] [2]
Clean the spark plug [1] electrodes with a wire brush [2]
or special plug cleaner.
Check the following and replace if necessary.
Insulator [3] and sealing washer [4] for damage
Center electrode [5] and side electrode [6] for wear
Burning condition, coloration
RECOMMENDED SPARK PLUG:
BPR6ES (NGK)
W20EPR-U (DENSO)
Measure the plug gap with a wire-type feeler gauge.
PLUG GAP: 0.70 0.80 mm (0.028 0.031 in)
[4]
If the measurement is out of the specification, adjust by
bending the side electrode.
Install the spark plug (page 3-11). [5]
[6]
[3]
SPARK PLUG REPLACEMENT

REMOVAL
The engine and the muffler becomes very hot

during operation and remains hot for a while after
stopping the engine. Be careful not to touch the
muffler while it is hot. Allow it to cool before
proceeding.
Disconnect the spark plug cap [1] and remove the spark
[2]
plug [2].
Clean around the spark plug base with compressed

air before removing the spark plug and be sure that
no debris is allowed to enter into the combustion
chamber.
INSTALLATION
Install and hand tighten the spark plug to the cylinder
head.
RECOMMENDED SPARK PLUG:
BPR6ES (NGK) [1]
W20EPR-U (DENSO)
Tighten the spark plug to the specified torque.
Connect the spark plug cap.
3-11
62Z4H000.book 12
dummyhead
MAINTENANCE
SPARK ARRESTER CLEANING
The engine and the muffler comes very hot during

operation and remains hot for a while after stopping
the engine. Be careful not to touch the muffler while
it is hot. Allow it to cool before proceeding.
STANDARD, SILENT TYPE

Remove the air cleaner (page 6-5).
[3] [2]
Disconnect the spark plug cap [1].
Remove the four screws (5 x 8 mm) [2] and muffler
protector [3].
Remove the screw (4 x 6 mm) [4] and spark arrester [5].
[4]
Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen [6] with a wire brush.
[5]
Check the spark arrester screen for damage. If the
screen is damaged, replace the spark arrester.
Install the spark arrester in the reverse order of
removal.
[1]
[6]
LOW PROFILE TYPE

Remove the two bolts (8 x 20 mm) [1], muffler [2] and
[1]
muffler gasket [3].
Remove the spark arrester [4].
Be careful to avoid damaging the screen.

Clean the carbon deposits from the spark arrester
screen with a wire brush.
Check the spark arrester screen for damage. If the
[3]
screen is damaged, replace the spark arrester.
Replace the muffler gasket with a new one and install [4]
the spark arrester in the reverse order of removal.
[2]
3-12
62Z4H000.book 13
dummyhead
MAINTENANCE
IDLE SPEED CHECK/ADJUSTMENT
Ensure the governor arm and governor arm shaft are
installed correctly (page 7-5).
Use a tachometer with graduations of 50 min-1 (rpm) or
smaller that will accurately indicate 50 min-1 (rpm)
change.
Start the engine and allow it to warm up to normal
operating temperature.
Turn the throttle stop screw [1] to obtain the specified
idle speed.
+ 200
IDLE SPEED: 1,400 min-1 (rpm)
150
[1]
VALVE CLEARANCE CHECK/

ADJUSTMENT
Inspect and adjust the valve clearance while the engine

is cold.
CHECK
Disconnect the spark plug cap [1] and remove the
[4] [1] [2]
following:
Breather tube [2]
Head cover bolt (6 x 12 mm) [3] (4)
Head cover [4]
Head cover packing [5]
[3] [5]
Set the piston near top dead center of the cylinder

[1] [3]
compression stroke (both valves fully closed) by pulling
the recoil starter slowly. When the piston is near top
dead center of the compression stroke, the triangle
mark [1] on the starter pulley [2] will align with the top
hole [3] on the recoil starter case [4]. Pull slowly.
If the exhaust valve is open, use the recoil starter to turn

the crankshaft one additional turn and align the triangle
mark on the starter pulley with the top hole on the recoil
starter case again.
[4] [2]
3-13
62Z4H000.book 14
dummyhead
MAINTENANCE
Insert a thickness gauge [1] between the valve rocker
arm [2] and valve stem [3] to measure the valve [1] [3] [2]
clearance.
VALVE CLEARANCE:
GX120/GX200:
IN: 0.15 0.02 mm (0.006 0.001 in)
EX: 0.20 0.02 mm (0.008 0.001 in)
GX160:
IN: 0.08 0.02 mm (0.003 0.001 in)
EX: 0.10 0.02 mm (0.004 0.001 in)
If adjustment is necessary, proceed as follows.
[2]
[3]
ADJUSTMENT
Hold the rocker arm pivot [1] and loosen the pivot
[3] [1]
adjusting nut [2].
Insert a thickness gauge [3] between the valve rocker
arm and the valve stem.
Adjust by turning the adjusting screw until there is a
slight drag on the feeler gauge.
VALVE CLEARANCE:
GX120/GX200:
IN: 0.15 0.02 mm (0.006 0.001 in)
EX: 0.20 0.02 mm (0.008 0.001 in)
GX160:
IN: 0.08 0.02 mm (0.003 0.001 in)
EX: 0.10 0.02 mm (0.004 0.001 in) [2]
Hold the rocker arm pivot and retighten the pivot

adjusting nut to the specified torque.
Recheck the valve clearance, and if necessary, readjust
the clearance.
Replace the head cover packing with a new one and
install the removed parts in the reverse order of
removal.
Route the high-tension cord and breather tube

properly (page 2-11).
3-14
62Z4H000.book 15
dummyhead
MAINTENANCE
COMBUSTION CHAMBER CLEANING
Remove the cylinder head (page 13-4).
[1]
Clean any carbon deposits from the combustion
chamber [1].
FUEL TANK AND FILTER CLEANING

fuel.
Remove the fuel tank (page 6-3).

[3]
Remove the fuel tank joint [1] and O-ring [2] from the
fuel tank [3].
Clean the fuel tank joint and fuel tank with non-
flammable solvent, and allow them to dry thoroughly. [2]
Check the screen of the fuel tank joint for clogs or
damage, replace if necessary.
Install a new O-rings to the fuel tank joint and install
them to the fuel tank.
Tighten the fuel tank joint to the specified torque.
TORQUE: 2 Nm (0.2 kgfm, 1.5 lbfft)
[1]
Install the fuel tank (page 6-3).
After installation, check for any signs of fuel leakage.
3-15
62Z4H000.book 16
dummyhead
MAINTENANCE
FUEL TUBE CHECK

fuel.
Check the fuel tube [1] for deterioration, cracks or signs

[1]
of leakage.
Replace if necessary.
When checking, GX160/GX200 remove the fan

cover (page 5-2).
3-16

GX120 160 200 UT2 English PDF

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

GX120 160 200 UT2 English PDF

Transféré par

Droits d'auteur :

Formats disponibles

62Z4H000.

How to use this manual

Improper service or repairs can create an unsafe

For Your Safety

Failure to properly follow instructions and

Important Safety Precautions

How to use this manual

How to use this manual

You WILL be KILLED or SERIOUSLY HURT if you dont follow instructions.

You CAN be KILLED or SERIOUSLY HURT if you dont follow instructions.

You CAN be HURT if you dont follow instructions.

Honda Motor Co., Ltd.

How to use this manual

Replace the part(s) with new one(s) before assembly.

Use the recommend engine oil, unless otherwise specified.

Use multi-purpose grease (lithium based multi-purpose grease NLGI #2 or equivalent).

Use marine grease (water resistant urea based grease).

Use automatic transmission fluid.

( x )( ) Indicates the diameter, length, and quantity of metric bolts used.

How to use this manual

Bl Black G Green Br Brown Lg Light green

SERIAL NUMBER LOCATION 1-2 ENGINE SPECIFICATIONS 1-11

P.T.O. TYPE VARIATION1-2 PERFORMANCE CURVES 1-12

DIMENSIONS AND WEIGHTS DIMENSIONAL DRAWINGS 1-15

P.T.O. TYPE VARIATION

*: P. T. O. type. (page 1-2)

(Nm) (lbfft) (kgfm)

(kW) (HP) (PS)

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

(Nm) (lbfft) (kgfm)

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

(Nm) (lbfft) (kgfm)

NET TORQUE 1.2

RECOMMENDED OPERATING SPEED RANGE

2000 3000 3600

ENGINE SPEED (rpm)

Dual/dual silent: 160 (6.3)

S type*: 75.5 (2.97)

H type*: 45.1 (1.78)

H, L type*: 106 (4.2)

H type*: 151.2 (5.95)

H type*: 370 (14.6)

Dual/dual silent: 160 (6.3)

419 (16.5) Standard: 93 (3.7)

S type*: 75.5 (2.97)

H type*: 45.1 (1.78)

H, L type*: 106 (4.2)

H type*: 151.2 (5.95)

Dual/dual silent: 160 (6.3)

S type*: 75.5 (2.97)

H, L type*: 106 (4.2)

H type*: 151.2 (5.95)

P type* Unit: mm (in) Q type* Unit: mm (in)

5/16-24UNF-2B 61.7 (2.43)

19.025 19.050 GX120: 78 (3.1) GX120: 19.000 19.050

S type* Unit: mm (in) T type* Unit: mm (in)

5.00 5.03 M8 X 1.25

GX120: 14.90 15.00 23 (0.9)

U type* Unit: mm (in) V type* Unit: mm (in)